Castle - Make A Special Edition Monster

[Pdelcast]

Originally Posted by GriffinRU

Fantastic! That what I was looking for. Can you add copper plate? And 5-6S support?

You do know that the copper plate and the Artic silver doesn't really make much difference right? What would make a big difference is to go to a pin-fin copper heat sink... like this one:

http://www.coolinnovations.com/produ...UltraCool4.php

[GriffinRU]

Originally Posted by Pdelcast

You do know that the copper plate and the Artic silver doesn't really make much difference right? What would make a big difference is to go to a pin-fin copper heat sink... like this one:

http://www.coolinnovations.com/produ...UltraCool4.php

Try to take an infrared picture of your ESC with and without copper plate, I do not really care about arctic silver...as long as you can keep it as flat as possible, you can use graphite if you can maintain below 0.005". You know there is a step with sand paper right, not only for adhesion.

Sure, there are even better things you can do. If your R&D budget can afford 2 month clean-room run, I can share with you what can be better and we can talk patenting...

[Pdelcast]

Originally Posted by GriffinRU

Try to take an infrared picture of your ESC with and without copper plate, I do not really care about arctic silver...as long as you can keep it as flat as possible, you can use graphite if you can maintain below 0.005". You know there is a step with sand paper right, not only for adhesion.

Sure, there are even better things you can do. If your R&D budget can afford 2 month clean-room run, I can share with you what can be better and we can talk patenting...

I have IR pictures of the ESC, and a copper plate doesn't make any significant difference on the 6oz board... the older 4oz board was a different story. And, a copper pin fin heatsink is actually an easier mod will have much more effect than a copper heat spreader.

BTW -- we are using the temp sensor on the processor -- so make sure any mods you do reduce the temp difference between the FETs and the processor, not the opposite.

What does that mean -- 2 month clean-room run? Are you thinking about getting On Semiconductor to give us some Fab time, or what?

[GriffinRU]

Originally Posted by Pdelcast

I have IR pictures of the ESC, and a copper plate doesn't make any significant difference on the 6oz board... the older 4oz board was a different story. And, a copper pin fin heatsink is actually an easier mod will have much more effect than a copper heat spreader.

BTW -- we are using the temp sensor on the processor -- so make sure any mods you do reduce the temp difference between the FETs and the processor, not the opposite.

What does that mean -- 2 month clean-room run? Are you thinking about getting On Semiconductor to give us some Fab time, or what?

Well, true for the last gen. pcb with only 6 fet's down there... still can see slight improvement. If you plan to add copper heatsink to MM, than I am sorry who needs MMM in 1/8 scale? You can do the same to MMM, of course. Just get plated copper, so it doesn't change its appeal :)

I know, on first versions I was adding copper spacer, but lately reusing your foam, works alright. :)

Something like that, but not at On Semiconductor, more like proto run at University and upon success, I do not know it is way too early.

[Pdelcast]

Originally Posted by GriffinRU

Well, true for the last gen. pcb with only 6 fet's down there... still can see slight improvement. If you plan to add copper heatsink to MM, than I am sorry who needs MMM in 1/8 scale? You can do the same to MMM, of course. Just get plated copper, so it doesn't change its appeal :)

I know, on first versions I was adding copper spacer, but lately reusing your foam, works alright. :)

Something like that, but not at On Semiconductor, more like proto run at University and upon success, I do not know it is way too early.

Well, the main problem we had with all of our Copper heatsink testing was that the heatsink is HEAVY -- and on crashes would sometimes rip the FETs off the board (or in half!)
The copper heat sinks did work very well, but were very expensive.

On Semiconductor has done some custom stuff for us in the past -- they might be willing to listen.

[GriffinRU]

Originally Posted by Pdelcast

Well, the main problem we had with all of our Copper heatsink testing was that the heatsink is HEAVY -- and on crashes would sometimes rip the FETs off the board (or in half!)
The copper heat sinks did work very well, but were very expensive.

On Semiconductor has done some custom stuff for us in the past -- they might be willing to listen.

There are ways to solve this, fet's case cannot support such load. Expensive way - hybrid heatsinks, all the way up to built-in heatpipes. Second one - pcb support for heatsink, you can solder heatsink to the board.

Well, now that is when we switch to PM.

By the way, I am pretty sure, you've seen that :)

[Pdelcast]

Originally Posted by GriffinRU

By the way, I am pretty sure, you've seen that :)

Sure is a lot easier to build a high power controller when you only have a single phase...

Probably just a couple Eupec IGBTs. Pretty simple. -- What isn't talked about is the RADIATOR that that controller requires -- and water pump, and plumbing... 2 watts of loss per amp just for forward drop, minimum.

IGBT drivers can be a challenge in three phase setups, but single phase is a breeze.

[Pdelcast]

Originally Posted by GriffinRU

By the way, I am pretty sure, you've seen that :)

You know, I've been thinking about this --

It wouldn't be too hard to do a 400V MOSFET based 3 phase controller for an EV. And it wouldn't be hard to do a PM motor for it either (expensive magnets though...) Both ST and Infineon have some nice 500V MOSFETs now (that don't have 1000nC charges.)

Need to sleep now, but I'm thinking about it.

[Arct1k]

Originally Posted by Pdelcast

I have IR pictures of the ESC, and a copper plate doesn't make any significant difference on the 6oz board... the older 4oz board was a different story. And, a copper pin fin heatsink is actually an easier mod will have much more effect than a copper heat spreader.

Is this a potential option for a more expensive MMM that doesn't need a fan? :)

Cheers